Thought Leaders Webinar

NECA WEBINAR SERIESThought Leaders WebinarPresented by NECA Business Partner

COMPRESSION LUGS AND LINKS

Biometal, Aluminium and Copper Cable Lug Crimping and Selection

15/07/2021

Webinar Agenda

Presenter:

1. The Lug and the link market2. Q&A

MIKE MATULEWICZ

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N E C A ’ s T H O U G H T L E A D E R ’ S W E B I N A R : L E G E N D C O R P O R AT I O N P T Y LT D

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1.The Lug and Link Market


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• Types – Compression and mechanical (bolted)• Numerous suppliers & various brands• Different dimensions – USA (CSA, UL), Europe (DIN)• Australia & NZ – unique dimensions• Low, medium & high voltages• Uninsulated and insulated• Copper, aluminium and bi-metals• Mechanicals with brass or aluminium – size ranging• Tests, compliance and certification?

Existing in the market


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Problems and IssuesMost failures due to:• Loose connections: vibration, torque, dirt,

obstructions, etc.• Environment effects: salt moisture, corrosive

atmospheres, animals, insects, etc.• Faulty installation – wrong tools, incorrect

installation, bad practices, careless, negligent, etc.• Time: installations age. Good maintenance

programs can prevent and help.


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Other Issues• Various dimensions – check for Australian/NZ tooling• Variety of conductors – e.g. flexible, cross section• Cost cutting by less metal - conductor• Proper test certification• Reputable lab tests • Variety of suppliers – good and questionable• Misleading information• Variety of standards e.g. UL vs AS/NZS


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Let’s Look at What We Will DiscussSubject Matter in this presentation:1. Electrical conductors2. Connectors i.e. lugs and links for electrical

conductors3. Compression lugs and links4. Mechanical lugs and links5. Standards and tests6. Current carrying7. Applications8. Installation9. Accessories


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Types of Electrical Cable ConductorIEC60228 classes of conductor for insulated cable• Class 1 – solid• Class 2 – stranded for fixed installation. Core has a

plurality of strands e.g. 3, 7, 19, 37, 61, 127, etc.

Stranded overall diameter is larger than solidStranded can be compacted or compressed

• Class 5 – flexible. Core has large number of strands• Class 6 – Very flexible

Strands can be bunched in ropes. Overall diameter larger than stranded.


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Types of Electrical Cable Conductor• Copper – hard drawn or annealed• Aluminium – usually an alloy• Solid round conductor – copper or aluminium• Solid sector – generally aluminium• Stranded sector – copper or aluminium• Stranded round – copper or aluminium• Milliken – grouped copper strands with insulating

separators

Copper Milliken

Solid sectorStranded sector


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Overhead Line Conductors• HDC – Hard Drawn Copper• AAC – All Aluminium• AAAC – All Aluminium Alloy• ACSR – Aluminium conductor steel reinforced• ACSR/GZ – Galvanised steel reinforcing• ACSR/AZ – Aluminised steel reinforcing• ACSR/AC – aluminium clad steel reinforcing• SC/GZ – Steel conductor galvanised• SC/AC - Steel conductor aluminium clad• ACCR – Aluminium composite reinforced


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Cross Sectional AreaDiameter = 2 x radius

Circumference = π x 2 x radius

π = number of times diameter fits in to a circle ≈ 3.14159

Radius = ½ x d

Area = 𝐴𝐴 = 𝜋𝜋𝑟𝑟2 = 𝜋𝜋(𝑑𝑑/2)2

Cross section = area of conductor


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Conductor StrandingCable stranding:• Presented as number of strands/diameter of strand• Example 7/2.0• D = 2 mm & r = ½ x 2• Cross section of this stranding = (1/2 x 2.0)2π x7

= 1 x 3.14159x 7= 21.99 sq. mm≈ 22 mm2

So you can work out the cross-sectional area of the conductor.Then select the lug or link.

d= 2mm


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Electrical Crimp ConnectorsCrimp Connection• Hexagon, most popular form in Australia and New Zealand• Proven method for over 70 years• Indent crimp method mainly used on uninsulated terminals• Indent crimp used for solid aluminium sector conductor• Other crimp methods are circular, quad indent and notch

crimp• Crimping is clean, easy and safe• Hand tools to heavy duty hydraulic tools are available• Before crimping, solder was the main method


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AF and Good CompactionCorrect Compaction,• Across the flat dimension• Critical – conductor & barrelUnder crimp• Loose connection• Hot jointOver crimp• Incorrect compaction• Die not closed to proper AF• Due to: flex, semiconductor, tolerances• WingingTest AF• Measure AF with Vernier Calliper – die & crimp


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Area of a Hexagon Crimp

Compare this to tables with crimp ratios for heat cycle and pull tests and we can deduce performance of the connection.

a = s x 0.866S = 2/ 3 x a2a = AF

Areahex = 0.866 (AF)2

If you know:1. Area of conductor2. Area of lug barrel3. Area of die when compressedThen you can calculate:Compression ratio as %. CSA of material: CSA of hex


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Construction of Lugs & TerminalsPalm

Stud Hole

Neck

Barrel

BarrelBarrier

Viewing Window

Hot forged palm

Friction Weld

Copper Lugs & Links• Pure annealed copper• Generally tinned• Cold forged• Large variety for many applications• Copper dimensioned diesAluminium Lugs & Links• Pure aluminium• Cold forged• Markings – crimp, AF, etc.• Al dimensioned diesBi-metal• For joining AL & Cu• Bl barrel same as Al• Reverse Bl same Cu


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TerminalsTerminals ≤ 10 sq. mm and less• Crimp dies – indent, hex, oval, pre-

insulated profile, roll crimp• Funnel entry• Pre-insulated – Std. & DG• Uninsulated• Made from stamped plate, rolled,

soldered and sleeved for pre-ins & DG

Bootlace ferrules• Copper sleeve to protect fine strands• Not subject to AS/NZS4437• Voltage – suitable for cable insulation • Requires light crimp – not to rely on

screw or clamp to crimp.

Standard Entry

Funnel EntryUninsulated

Bootlace Ferrules

Pre-insulated

Roll crimp


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Mechanical Lugs and LinksAdvantage:

• Range taking• Usually bi metal• Basic tools to install• Used in joint kits• Stock reduced

Disadvantage:• Expensive• High Vibration• Large & cumbersome• Manual installation


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Test StandardsTerminals, ≤ 10 mm2

• AS/NZS4437 - terminals• AS/NZS3169 – flat connector terminals• Tension test required

Lugs and links ≥16 mm2 including mechanical• AS/NZS4325• Class B: tension and heat cycle. Class A includes short circuit current

pulse

Overhead lines joints & fittings• AS1154.1• Tension required. Heat cycle and short circuit are optional• Class A – heat cycle. Class B – heat cycle and short circuit pulse


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TestingTension AS/NZS4325: Al – 40 x A: max 20kN

Cu – 60 x A: max 20kNAS 1154.1: FT - Preload to 50% CBL

- Test Load 90% CBL 1 min NT - initial 5%CBL and test 10% for 1 min

Heat CycleAS/NZS4325: Class B 1000 cyclesAS 1154.1: FT 250 at 80°C with 2.5% CBL

NT 2.5% tension & 250 for compression,500 for other fittings.


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Authentic Certificates & ReportsNATA Accreditation – CABAC Lab in SydneySome labs may do incomplete tests – not always to a standard.

Look for completion of the standard• Report & Certificate with PASS (not conforms to) Some suppliers

use “conform or complies”• Conform or compliance can mislead• All cycles must be complete• AS/NZS4325: 1000 heat cycles (check to see cycles complete)• AS1154.1: 250 heat cycles for compression (optional)• Check that the test sequence matches the standard – check

tables in standard• AS/NZS4325 very stringent compared to UL


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Current Carrying CapacityGeneral• Lugs and links will carry the same current as the

conductor• Long barrel Cu lugs perform better in service and tests• The barrel is the main focus of tension and heat cycle

tests• The palm connection – connection has greater area than

the cross section of the conductor• Lugs require a good high tensile bolt torqued to almost

maximum• Stainless steel requires anti-seize paste suitable for

copper and stainless steel.


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Current Carrying CapacityLow Voltage:Current carrying capacity is the same as for the cable

Medium Voltage connectionsMV bushing terminations• AS62271.301-2000 HV switchgear• Bushings and connection Al. 0.17A/mm2 & Cu 0.32A/mm2.

Torque levels for terminations


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ApplicationsLugs and terminalsUsed at conductor ends to connect to a device i.e. a termination

Links, sleeves and splicesUsed to join conductorSometimes called barrel lugs


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Outdoor & Indoor ApplicationsCabac Lugs: Suitable applications:• Outdoor use – sealed from elements• Long barrel and long barrel long palm Cu lugs are

suitable for outdoor terminations• Standard Cu lugs available for outdoor have no

window• Standard Al lugs suitable for outdoor• Long barrel Al lugs indoor only• Bi-metal lugs suitable for indoor and outdoor –

standard & LPB


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Applications – Range to Suit• Cu Bell Mouth – flex• Circuit breaker lugs• Double crimp• Links standard and barrier• Reducing links• Switchgear lugs reverse bi-metal• Double barrel lug• Sector lugs• Overhead conductors• Full tension sleeves• Braids• Custom designs and applications


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Application – Earthing – Bonding and Buried Earth ConnectionsBonding and connections above groundCACC range

Lugs – earth connectionsHeavy duty lugsLong barrel, long palm

Buried connections CACD IEEE837 to 95 sq. mmCACE IEEE837 to 95 sq. mmEarth Rod connectionsCAEC70 IEEE 837, 70 sq. mm only

CACC

CACD CACE

CAEC70

CAL500LPB


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Indent CrimpingIndent CrimpingGenerally used up to 16 sq. mmCan be used on copper lugs up to 120 sq. mmUsed on solid aluminium sector conductor.


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Pre-Insulated Terminals3 sizes generally used• Red – 0.5 to 1.6 mm2

• Blue – 1.0 to 2.6 mm2

• Yellow – 2.55 to 6 mm2

Crimping Tools• KTC1, KTC3, HP3, KFLAG, etc.• Die – oval type shaped crimp• Strip length 4-5 terminals & 7 to 8 mm

for splices


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Bootlace Ferrules

Bootlace Ferrules• Flex panel wire• Sizes from 0.25 to 150 sq. mm

(Cabac 120)• Colour marked (insulated)• Sleeve only (uninsulated)• Twin conductor sleeves• Must crimp with suitable tool

Fit Crimp self adjusting

Crimp selected size Trim


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InstallationCompression connectors• Use the right tool, the correct die and the

suitable connector• Cable preparation essential• Special cable preparation tools available• Work in clean conditions• Remove dirt, aluminium oxide, water block,

semiconductors, etc.• Milliken cable remove all barriers• Dress and clean after installation• Al lugs & links – use compounds

Stripping tools

Jointing Compound

Crimp tool

Abrasive Paper


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Hexagonal CrimpingDies• Hexagon must have equal sides – if not second crimp could distort

shape

Tooling• Hex crimping with 13/12 ton tool C dies up to 300sq. mm for

aluminium and 400 sq. mm for copper.• 5 ton tools – 6 to 185 sq. mm. M dies are thinner than 13 ton C dies.• 3.5 ton – for Australian lugs and links up to 95 sq. mm

Note: Die must close to form proper hex. Test across the flat with Vernier calliper.


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Heavy Crimping Tools• 23/22 ton crimping head – can use 13t on C dies with

an adaptor. Large dies - 400 to 630 sq. mm for copper & up to 500 sq. mm for aluminium

• 50/52 ton crimping head – can use 13 ton C dies with an adaptor. Large dies – 400 to 1000 sq. mm.

• 60 ton crimping head – large C dies for 240 to 1200 sq. mm copper and up to 1000 sq. mm for aluminium

• Crimping heads – foot pump or electrically power pumps.


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HEX Crimping• Cabac catalogue lists number of crimps• The number of crimps listed depends on tension and

heat cycle tests.• The tools used are generally 13 ton hydraulic up to

300 sq. mm• Larger sizes will use 23 and 52 ton heads as suits the

appropriate die.• Compact cable from 95 to 185 sq. mm requires at

least two overlap crimps and not the listed one• M dies for 5 ton and 3.5 ton require more crimps to

match the tool used in tests• Hand tools like KO6 requires three crimps for every

one with a 13 ton tool.


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Aluminium Connectors• Aluminium lugs cannot be connected to copper cable or

bare busbar• Tinned aluminium can be connected to copper or

aluminium• Aluminium oxide forms a high resistance. It must be

removed• Aluminium lugs and links has different dies to copper


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Bimetal Connectors• Bi-metal connectors i.e. aluminium to copper or vis

versa• Copper & Aluminium – special friction weld• There is no paste available to join aluminium to copper• Tinned aluminium is considered to be a bi-metal• Shear bolt connectors are tinned to join Cu & Al• Bi-metal aluminium barrels are the same as aluminium

barrels• The aluminium section uses the same dies as for

aluminium• Reverse bi-metal lugs – connect copper cable to

aluminium terminals


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Certification of TestsCertificates are available on request

Loose and hot connections are a major cause of equipment failure.Precautions to minimise hot connections:• Use the right connector with the correct tool for the

applicable application• Fasten a lug properly – torque the bolt to almost its

recommended max level• Use high tensile bolts• Use anti-seize paste with stainless steel bolts• Use washers and spring washers or bevelled washers or

locking nuts


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Jointing CompoundsJoint compounds:• Improve connection• Protect against corrosion• Fills voids• Prevents oxidisation• Prevents water ingress

Additives:• Improve connection – Cu, Zn• Silica increases friction & hold

Base: Oils – not conductiveUse correct compound for its specific purpose

Use – Copper or Aluminium• Bolted• Compressed• Mechanical strength - friction


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Crimping Compact CableCompact Conductor• Compressed to save on material; pre-crimped• Lug may fit loosely• The cross section is still as per specification• Do not reduce lug size• Use lug for the specified cross section• Compression die will crimp to required cross section• Use 2 crimps for standard Cu Lugs 95 to 185 sq. mm


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Solid and Stranded ConductorSolid Sector Conductor• Aluminium only• Indent crimp or hex• 3 or 4 core cable• Sector lugs and links• Rotating barrel

Stranded Sector• Aluminium or copper• 3 or 4 core cable• Use standard round barrel• Adjust strands to fit• Rounding die available


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Crimping Fine StrandFine stranded – flexible and very flexibleClass 5 & 6 according to IEC60228

Fine strands:• Require more force• Have larger diameters• Can be difficult to fit or too large

• 1.5 to 16 sq. mm – likely to fit – crimp normally• 25 to 150 sq. mm – bell mouth should fit in most cases• 185 plus sq. mm – unlikely to fit – use ½ & ½ crimp method

½ & ½ technique:• Lug one size up• Crimp with that lug size die• Then remove ½ the die• Replace ½ with die for conductor size and crimp• 2nd crimp ½ conductor size & ½ one size up.


LV, MV and HVAS/NZS4325 - load (current) and aging (cold flow) regarding the barrel

Compression lugs and links suitable for LV, MV & HV

MV & HV – other considerations:• No sharp edges or burrs• Concentric conductor placement for MV & HV• Care taken regarding corona• ½ & ½ technique may not be suitable.• Fine strand – alternative die and barrel


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Accessories for TerminationsCable preparation toolsToolingCable clampsCable tiesJoint & termination kitsHeat and cold shrinksMarking systemsTest equipment


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Video ReferenceYOUTUBE – CABAC – crimping videosGo to Cabac web site/resources/CABAC YouTube Channel

https://www.youtube.com/user/CabacVideoTraining/videos

WWW.CABAC.COM.AU


https://www.youtube.com/user/CabacVideoTraining/videos

http://www.cabac.com.au/

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FINALLYThe Right Lug

The Right Tooling forFor the Right Connection


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Q&A

1300 361 099 neca.asn.au [email protected]


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